Air conditioning system made up of modular components



Nov. 30, 1965 A, LEPPARD ETAL 3,220,711

AIR CONDITIONING SYSTEM MADE UP OF MODULAR COMPONENTS Filed April 11. 1961 2 Sheets-Sheet 1 W NIMNIIIIIIIHI Fl G 5 INVENTOR.

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ZMw @7 2 United States Patent 6 3,220,711 AIR CONDITKONlNG SYSTEM MADE UP F MGDULAR COMPONENTS Benjamin A. Leppard, Greenville, S.C., and Robert M. Warren, Jr., Charlotte, N.C.; said Warren assignor to Buensod-Stacey Corporation, New York, N.Y., a corporation of ()hio Filed Apr. 11, 1961, Ser. No. 102,209 2 Claims. (Cl. 261-133) The present invention relates to air conditioning systems and particularly to a new and improved air conditioning system that is made up of modular components.

It has been generally recognized for some number of years that the so-called central station split system was the best possible means of providing desired atmospheric conditions for industrial processes such as textile manufacturing processes and the like. This system employs minimum air quantity with space mounted atomizers to boost humidity. Refrigeration, where required, is utilized to maintain desired temperature levels. Basically, the design of these systems includes the use of dehumidifiers, main supply air fans and controls. Main improvements over the years have consisted of the use of vane-axial fans in lieu of centrifugal and the development of automatic lint filters. Both of these items have served to reduce maintenance costs and these, with the development and improvement of control systems, have continued to keep the central station as the most desired system.

Central stations are easily adaptable to dewpoint control and regulation of capacity to meet load changes by use of bypass dampers, thus providing what is generally accepted as the best possible control for uniformity and stability of room conditions.

Due to the designed arrangement of the central station type, the size of the equipment requires construction of apparatus rooms and towers which consume a sizeable portion of each dollar spent for air conditioning. With from one-fourth to one-third of the total cost of installing air conditioning spent for housing of equipment only, the cost of the central station has been prohibitive in many cases, though desired from many other standpoints. As a result, there have been many efforts to develop a system that would not require expensive housing.

The biggest promise in recent years for a system that would retain advantages of central station, yet not incur expensive building, has been the development of a space mounted, high pressure, high velocity dehumidifier. Such being somewhat compacted due to the high velocities maintained in the unit, such a unit still occupies a large volume of space. It can be installed outdoors without housing on the roof or suspended from the walls, but its comparatively heavy weight does require some structural considerations. The system also lacks some of the chief advantages of central station due to the fact that dew-point control cannot be utilized and bypass arrangement is not possible. The system depends upon washer spray throttling and steam reheat for capacity regulation. Operating cost in terms of power requirements is much higher than the central station type due to the high velocities in the unit and use of steam for capacity regulation.

The principal object of this invention is to provide a system to overcome the disadvantages of both the two systems described above.

Another object of the invention is to provide such a system that is made up of modular components that can be assembled in a variety of ways to accommodate varying industrial conditions.

3,220,711 Patented Nov. 30, 1965 Still another object of the invention is to provide right and lefthand modular components of two types that will cover a wide variety of arrangements to produce such an air circulating and conditioning system.

Still another object of the invention is to provide two forms, i.e., right and lefthand modular filtering components for receiving the return air.

A further object of the invention is to provide two forms, i.e., right and lefthand modular washing and heating components for use with the above described filtering modules.

In one aspect of the invention, an air conditioning system may be made up of multiples of two of right and lefthand filtering and washing modules that may be of relatively light construction and which may be attached to the outside wall of a building in order not to consume valuable space within the building.

In another aspect of the invention, the filtering modules may be left and righthand. They may comprise a substantially rectangular housing which may be made up of walls comprising two spaced layers of sheet metal such as aluminum or the like between which may be sandwiched a suitable insulating material such as asbestos, glass wool, plastic fibers or the like. The one longitudinal wall may have an opening for cooperating with suitable filtering elements. Beneath the filtering elements may be a partition within which may be a series of adjustable dampers. The other longitudinal wall may include an opening beneath the bafile for admitting outside air to the filtering module. One of the end walls may include an opening at its top and bottom. The only difference between a right and lefthand filtering module is that the end wall of each containing the top and bottom openings is opposite the other.

In still another aspect of the invention, a washing and heating module may comprise a rectangular housing similar to that for the filtering module, and it may include a top and bottom opening in one of its end walls that may register with corresponding top and bottom openings in the end wall of the corresponding filtering module. There may be a duct opening in the one longitudinal wall of the washing module near the top thereof for passing the conditioned air into distributing ducts leading to the zones being treated. Beneath the distributing duct opening may be a batfie supporting a moisture eliminator. An air heating element may be mounted adjacent the registering top openings in the sides of adjoining filtering and washing modules, and damper means may be located within said registered openings for controlling the amount of filtered air that is bypassed to the distribution ducts without being mixed with incoming air and washed.

Beneath the eliminators, in the washing module, may be spray nozzles for emitting a spray of water for washing incoming air. Beneath the spray nozzles may be located an opening in the end wall that registers with a corresponding opening in the one end wall of an adjacent filtering module. An arrangement of adjustable bafiles may be located within these registering openings for controlling the flow of mixed outside and inside air that flows through the washing spray.

With right and lefthand filtering and washing modules, it is apparent that various arrangements may be made to accommodate a wide variety of different industrial conditions. Thus, while a combination of washer, filter, filter, washer may be employed as shown in the drawings, other arrangements may be employed such as washer, filter, washer, filter; or filter, washer, filter, washer; or filter, washer, washer, filter.

The above, other objects and novel features of the invention will become apparent from the following specification and accompanying drawings which are merely exemplary.

In the drawings:

FIG. 1 is a front elevational view of four modules forming an air conditioning system to which the principles of the invention have been applied;

FIG. 2 is a sectional elevational View taken substantially along line 22 of FIG. 3;

FIG. 3.is a sectional plan view taken substantially along line 3-3.0f FIG. 2;

FIG, 4 is a sectional elevational view taken substantially along line 4-4 of FIG. 3; and

FIG. 5 is a sectional elevational view taken substantially along line 5--5 of FIG. 3.

Referring to the drawings, and particularly to FIGS. 1 and 2, the principles of the invention are shown as applied to modular components 10, 11, 12 and 13 of substantially the same size and supported on a framework 14 rigidly attached to the outside Wall of a building having zones adapted to be air conditioned.

The modules and 13 may be identical, combined washing and heating units except that module 10 may be righthand, and module 13 may be lefthand as will be explained later. The modules 11 and 12 may be identical filtering units except that 11 may be lefthand, while 12 may be righthand. A working unit may comprise modules 10, 11; or 12 and 13; and multiples of these two units may be employed to meet a wide variety of field conditions.

Referring to FIGS. 3 and 4, each of the modules 10 and 13 is shown as comprising four side walls 15, 16, 17, 18,a top wall 19, and a bottom wall 20. It is to be understood, however, that certain of the modular components may have three side walls, top and bottom, if desired. Each wall may comprise two spaced sheets of sheet metal such as aluminum or the like, between which may be sandwiched a layer of insulating material such as glass wool, felt or the like. Usually about a two-inch wall is suflicient to prevent condensation within the units 11 and 12, although condensation with in the washing units 10 and 13 is unobjectionable. Referring to FIGS. 3 and 4, the wall 16 near the top thereof may include an opening 21 adapted to register with an opening 22 within the building wall 23. The opening 22 may be hermetically sealed to a duct 24 leading to a fan 25 as will be explained later.

Directly beneath the duct opening 22 (FIG. 4) may be a partition 26 in the form of a moisture eliminator which may comprise a herringbone arrangement of minute passages as shown in FIG. 2.

The wall 17 of the module 10 may include an opening 27 near its upper extremity, and a heating unit 28 may be located above and supported by the partition 26 and inwardly of the wall 17. One or more water lines 29, 30 may be located beneath the partition 26, and each may be provided with a plurality of spray nozzles 31. The wall 17 may also include an opening 32 near its bottom for a purpose to be disclosed later. The only difference between modules 10 and 13 is that the openings 27 and 32 are located in wall 15 of module 13, and the heater 28 is located near wall 15 instead of wall 17.

The module 11 may be substantially the same size as the modules 10 and 13. It may include four walls 33, 34, 35 and 36 (FIG. 3), a top wall 37, and a bottom wall 38. The wall 33 may include an opening 39 near its upper extremity that registers with the opening 27 in the wall 17 of module 10. A bypass damper 40 may be mounted within the registering openings 27 and 39, and it may include a plurality of pivotally mounted louvers 41 for varying the quantity of air that may be bypassed from module 11 to module 10, as will be explained later.

The wall 34 may include an opening 42 (FIG. 3) that may register with an opening 43 in the building wall 23. Filter units 44 and 45 may be mounted within the opening 43 for filtering return air to be conditioned.

Beneath the opening 42 may be a horizontally disposed partition 46 that supports a damper means 47 including a plurality of pivotally mounted louvers 48 (FIG. 5).

The wall 33, containing the opening 39, may also include an opening 49 near the bottom thereof for registering with opening 32 in wall 17 of module 10. The wall 36 (FIG. 5) of module 11 may be provided with an opening 50 within which may be mounted an air intake unit comprising adjustable louvers 51 and adjustable dampers 52. The wall 34 may also include an opening 53 that registers with an opening 54 in wall 23 that may be closed by an access door 55. This construction makes it possible to adjust and clean the dampers 47 and 52.

The only difference between modules 11 and 12 resides in the fact that the openings 39 and 49 are located in wall 35 of module 12, whereas these openings are in wall 33 of module 11.

From the foregoing it is evident that modules 10 and 13 are right and lefthand units, respectively, as are modules 12 and 11. It becomes apparent, therefore, that various combinations of the modules 10 to 13 may be made for satisfying varying conditions. Thus, in the disclosure of FIGS. 1, 3 and 4, a righthand module 10 is located in abutting relation to a lefthand module 11; and a righthand module 12 abuts a lefthand module 13.

In the arrangement shown, the damper unit 40 is located within the registering openings 27, 39; and an air inlet 56 with adjustable baflles 57 is mounted within registering openings 32 and 49. Similarly another damper unit 40 is located within the openings 27 and 39 between walls 15 and 35 of modules 13 and 12; and an air inlet 56 is mounted within openings 32 and 49 in walls 15 and 35 of modules 13 and 12.

It is evident, however, that the arrangement shown in FIG. 4, namely, wash, filter, filter, wash, can be rearranged in various alternative patterns. Thus, by replacing modules 10 and 11 with module 12 and 13, the arrangement will be filter, wash, filter, wash. Again, by replacing modules 12 and 13 with modules 10 and 11, the arrangement will be wash, filter wash, filter. =Futhermore, only two modules such as 10, 11 or 12, -13 may be employed. Thus it is evident that the module construction provides wide flexibility for satisfying various field demands.

Referring to FIG. 3, the ducts 24 lead to fans 25 which may be of the vane axial type which deliver the conditioned air through ducts 57, 58 to a distributor '59 having a splitter 60 for controlling the flow of air to distribution ducts 61 and 62. Vanes 63 may be located at locations in the duct system in which the path of air flow is to be changed in flowing to the various distribution ducts.

Referring to FIG. 2, the water from nozzles 31 collects within the bottom of the modules 10 and 13 and it may be drained through lines 64 into a washer recirculating tank 65 at any convenient location. The tank 65 may be provided with screen means 66 for removing foreign materials washed from the air circulating through the Washer module, and an overflow 67 that may run to the outside or to any convenient drain. The tank 65 may have an outlet line 71 that may lead through a recirculating pump to the supply lines 29 and 30 for the recirculation of the washing water. The tank 65 may also include a battle or weir 68 forming a chamber 69 into which may overflow any chill water which may be added to the recirculating water for control purposes. Chamber 69 may have an outlet line 70 for returning this excess water to the refrigeration equipment for chilling and return to the recirculating system.

From the foregoing it is evident that an air conditioning system comprised of modular components has been provided which has great flexibility not only in regard to component arrangement but also with respect to operation. Thus, by adjusting the dampers 40, the return air dampers 47, the outside air intake dampers 52 and the baffles 57, a predetermined amount of washed outside air may be introduced to the system while only the recirculated air is heated by the units -28. Chilled water can be fed to the spray washers as needed and suitable control systems as known in the art utilized. It can be seen that a great variety of conditions can be satisfied by the adjustment of the above described bafiies and dampers. Furthermore, the mounting of the modular components on the outside wall of the building conserves valuable space within the building.

Although the various features of the new and improved air conditioning system have been shown and described in detail to fully disclose one embodiment of the invention, it will be evident that changes may be made in such details and certain features may be used without others without departing from the principles of the invention.

What is claimed is:

1. In an air conditioning system for a Zone in a building, a pair of modular components adapted to be sup ported side by side on a wall of a building having a zone to be air conditioned, said pair of components being a working unit consisting of right and left hand modules, each of said components comprising side walls, a top wall and a bottom wall with left and right hand side walls abutting; one of said components including washer spray means; another of said components including means for receiving return air from the zone being conditioned, as well as means for receiving outside air; flow control means in said outside air receiving means; the abutting side walls of said components having registering opening means near the top and bottom of said components for establishing communication between said components; flow control means within said opening means; a partition between said return air receiving means and said outside air receiving means; flow control means in said partition means; partition means adjacent said washer spray means; and a heating unit supported by said last named partition means.

2. In an air conditioning system for a zone in a building, two modular components each having side walls, a top wall and a bottom wall; said two components being a working unit consisting of right and left 'hand modules, opening means at the top and bottom in the opposite end side walls of each component; water spray means within each of said components; a partition above said water spray means; a heating unit supported by the partition above said water spray means; two additional modular components arranged side by side with each having side walls, a top wall and a bottom wall, said two additional components being a working unit consisting of right and left hand modules; air return means in a side wall of said last mentioned components; a partition beneath said air return means; both said partitions having air passage means; opening means at the top and bottom in the opposite end side walls of each of said last mentioned components adapted to register with the opening means in the opposite end side walls of said first mentioned components; and flow control means within said opening means.

References Cited by the Examiner UNITED STATES PATENTS FOREIGN PATENTS 10/ 1953 Germany.

HARRY B. THORNTON, Primary Examiner.

HERBERT L. MARTIN, RONALD R. WEAVER,

Examiners. 

1. IN AN AIR CONDITIONING SYSTEM FOR A ZONE IN A BUILDING, A PAIR OF MODULAR COMPONENTS ADPATED TO BE SUPPORTED SIDE BY SIDE ON A WALL OF A BUILDING HAVING A ZONE TO BE AIR CONDITIONED, SAID PAIR OF COMPONENTS BEING A WORKING UNIT CONSISTING OF RIGHT AND LEFT HAND MODULES, EACH OF SAID COMPONENTS COMPRISING SIDE WALLS, A TOP WALL AND A BOTTOM WALL WITH LEFT AND RIGHT HAND SIDE WALLS ABUTTING; ONE OF SAID COMPONENTS INCLUDING WASHER SPRAY MEANS; ANOTHER OF SAID COMPONENTS INCLUDING MEANS FOR RECEIVING RETURN AIR FROM THE ZONE BEING CONDITIONED, AS WELL AS MEANS FOR RECEIVING OUTSIDE AIR; FLOW CONTROL MEANS IN SAID OUTSIDE AIR RECEIVING MEANS; THE ABUTTING SIDE WALLS OF SAID COMPONENTS HAVING REGISTERING OPENING MEANS NEAR THE TOP AND BOTTOM OF SAID COMPONENTS FOR ESTABLISHING COMMUNICATION BETWEEN SAID COMPONENTS; FLOW CONTROL MEANS WITHIN SAID OPENING MEANS; A PARTITION BETWEEN SAID RETURN AIR RECEIVING MEANS AND SAID OUTSIDE AIR RECEIVING MEANS; FLOW CONTROL MEANS IN SAID PARTITION MEANS; PARTITION MEANS ADJACENT SAID WASHER SPRAY MEANS; AND A HEATING UNIT SUPPORTED BY SAID LAST NAMED PARTITION MEANS. 